1989 FORD FIESTA engine

7Inspect the rotors for obvious signs of wear
or damage, and renew if necessary; if either
rotor, the pump body, or its cover plate are
scored or damaged, the complete oil pump
assembly must be renewed.
8 The oil pressure relief valve can be
dismantled, if required, without disturbing the
pump. Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support” ). Remove
the front right-hand roadwheel and auxiliary
drivebelt cover (see Chapter 1) to provide
access to the valve.
9 Unscrew the threaded plug, and recover
the valve spring and plunger (see
illustrations) . If the plug’s sealing O-ring is
worn or damaged, a new one must be
obtained, to be fitted on reassembly.
10 Reassembly is the reverse of the dismantling procedure; ensure the spring and
valve are refitted the correct way round, and
tighten the threaded plug securely.
Refitting
11
The oil pump must be primed on
installation, by pouring clean engine oil into it,
and rotating its inner rotor a few turns.
12 Using grease to stick the new gasket in
place on the cylinder block/crankcase, and
rotating the pump’s inner rotor to align with
the flats on the crankshaft, refit the pump and
insert the bolts, tightening them lightly at first
(see illustration) .
13 Using a suitable straight edge and feeler
gauges, check that the pump is both centred
exactly around the crankshaft, and aligned
squarely so that its (sump) mating surface is
exactly the same amount - between 0.3 and
0.8 mm - below that of the cylinder
block/crankcase on each side of the
crankshaft (see illustration) . Being careful
not to disturb the gasket, move the pump into
the correct position, and tighten its bolts
to the specified torque wrench setting.
14 Check that the pump is correctly located;
if necessary, unbolt it again, and repeat the
full procedure to ensure that the pump is
correctly aligned.
15 Fit a new crankshaft right-hand oil seal
(see Section 15).
16 Using grease to stick the gasket in place
on the pump, refit the pick-up/strainer pipe,
tightening its screws and nut to their specified
torque wrench settings (see illustration).17
The remainder of reassembly is the
reverse of the removal procedure, referring to
the relevant text for details where required.15 Crankshaft oil seals -
renewal
4
Note: Don’t try to prise these seals out without
removing the oil pump or seal carrier - the
seals are too soft, and the amount of space
available is too small, for this to be possible
without considerable risk of damage to the seal
housing and/or the crankshaft journal. Follow
exactly the procedure given below.
Right-hand seal
1 Remove the oil pump (see Section 14).
2 Drive the oil seal out of the pump from
behind (see illustration) .
3 Clean the seal housing and crankshaft,
polishing off any burrs or raised edges, which
may have caused the seal to fail in the first
place.
4 Refit the oil pump (see Section 14). Grease
the lips and periphery of the new seal, to ease
installation.
5 To fit a new seal, Ford recommend the use
of their service tool 21-093A, with the
crankshaft pulley bolt, to draw the seal into
place; an alternative can be arranged using a
socket of suitable size, with a washer to
match the crankshaft pulley bolt (see
illustration) .
2C•14Zetec engine in-car repair procedures
15.5 Socket of correct size can be used to
replace Ford service tool, drawing new
seal into place as described15.2 Driving out crankshaft right-hand oil seal14.16 Use new gasket when refitting oilpick-up pipe to pump
14.13 Oil pump must be positioned accurately
14.12 Use new gasket when refitting oil pump14.9b . . . to withdraw oil pressure reliefvalve spring and plunger14.9a Unscrew threaded plug - seenthrough right-hand wheel arch . . .
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6If such tools are not available, press the
seal squarely into place by hand; tap it in until
it is flush with the pump housing, using a soft-
faced mallet and a socket with an outside
diameter only slightly smaller than the seal’s
(see illustration) . This approach requires
great care, to ensure that the seal is fitted
squarely, without distortion or damage.
7 Wash off any traces of oil. The remainder of
reassembly is the reverse of the removal
procedure, referring to the relevant text for
details where required. Check for signs of oil
leakage when the engine is restarted.
Left-hand seal
8 Remove the transmission (see the relevant
Part of Chapter 7).
9 Where appropriate, remove the clutch
(Chapter 6).
10 Unbolt the flywheel/driveplate (see
Section 17).
11 Remove the sump (see Section 13).
12 Unbolt the oil seal carrier (see
illustration) . Remove and discard its gasket.
13 Supporting the carrier evenly on wooden
blocks, drive the oil seal out of the carrier from
behind (see illustration) .
14 Clean the seal housing and crankshaft,
polishing off any burrs or raised edges, which
may have caused the seal to fail in the first
place. Clean also the mating surfaces of the
cylinder block/crankcase and carrier, using a scraper to remove all traces of the old gasket
- be careful not to scratch or damage the
material of either - then use a suitable solvent
to degrease them.
15
Use grease to stick the new gasket in
place on the cylinder block/crankcase, then
offer up the carrier (see illustration).
16 Using a suitable straight edge and feeler
gauges, check that the carrier is both centred
exactly around the crankshaft, and aligned
squarely so that its (sump) mating surface is
exactly the same amount - between 0.3 and
0.8 mm - below that of the cylinder
block/crankcase on each side of the
crankshaft (see illustration) . Being careful
not to disturb the gasket, move the carrier into
the correct position, and tighten its bolts to
the specified torque wrench setting.
17 Check that the carrier is correctly located;
if necessary, unbolt it again, and repeat the
full procedure to ensure that the carrier is
correctly aligned.
18 Ford’s recommended method of seal
fitting is to use service tool 21-141, with two
flywheel bolts to draw the seal into place. If
this is not available, make up a guide from a
thin sheet of plastic or similar, lubricate the
lips of the new seal and the crankshaft
shoulder with grease, then offer up the seal,
with the guide feeding the seal’s lips over the
crankshaft shoulder (see illustration) . Press
the seal evenly into its housing by hand only, and use a soft-faced mallet gently to tap it
into place until it is flush with the surrounding
housing.
19
Wipe off any surplus oil or grease; the
remainder of the reassembly procedure is the
reverse of dismantling, referring to the relevant
text for details where required. Check for signs
of oil leakage when the engine is restarted.
16 Engine/transmission mountings -
inspection and renewal
1
Inspection
1 The engine/transmission mountings seldom
require attention, but broken or deteriorated
mountings should be renewed immediately, or
the added strain placed on the driveline
components may cause damage or wear.
2 During the check, the engine/transmission
must be raised slightly, to remove its weight
from the mountings.
3 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support” ). Position
a jack under the sump, with a large block of
wood between the jack head and the sump,
then carefully raise the engine/transmission
just enough to take the weight off the
mountings.
Zetec engine in-car repair procedures 2C•15
15.13 . . . and ensure that carrier is
properly supported when driving out used oil seal - note notches provided in carrier for drift15.12 Unscrew bolts (arrowed) to removecrankshaft left-hand oil seal carrier . . .15.6 If seal is tapped into place as shown,exercise great care to prevent seal from being damaged or distorted
15.18 Using guide made from thin sheet ofplastic to slide oil seal lips over crankshaft
shoulder15.16 Oil seal carrier must be positionedaccurately15.15 Use new gasket when refitting left-hand oil seal carrier
2C
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4Check the mountings to see if the rubber is
cracked, hardened or separated from the
metal components. Sometimes, the rubber
will split right down the centre.
5 Check for relative movement between each
mounting’s brackets and the engine/
transmission or body (use a large screwdriver
or lever to attempt to move the mountings). If
movement is noted, lower the engine and
check-tighten the mounting fasteners.
Renewal
6 The engine mountings can be removed if
the weight of the engine/transmission is
supported by one of the following alternative
methods.
7 Either support the weight of the assembly
from underneath using a jack and a suitable
piece of wood between the jack saddle and
the sump or transmission (to prevent
damage), or from above by attaching a hoist
to the engine. A third method is to use a
suitable support bar with end pieces which
will engage in the water channel each side of
the bonnet lid aperture. Using an adjustable
hook and chain connected to the engine, the
weight of the engine and transmission can
then be taken from the mountings.
Engine front right-hand mounting
8 This mounting consists of a two-piece
bracket bolted to the inner wing panel,
connected by the bonded-rubber mounting
itself to a (Y-shaped) bracket, bolted (via the
alternator mounting bracket) to the cylinder
block (see illustration) .
9 Unscrew the three bolts securing the front
right-hand mounting bracket to the alternator
mounting bracket.
10 Unscrew the bolts securing the mounting
bracket to the inner wing panel and chassis
rail and withdraw the mounting assembly.
Engine rear right-hand mounting
11 This mounting consists of the bonded-
rubber mounting secured to the inner wing
panel by a (horizontal) bolt, accessible from
within the wheel arch, and a (vertical) stud, the
retaining nut of which is accessible from the
engine compartment. The mounting is bolted
to a bracket, which is in turn bolted to the
cylinder block.
12 Unbolt the mounting from the body by
unscrewing first the single nut (and washer)
immediately to the rear of the timing belt
cover, then the bolt in the wheel arch.
13 Unbolt the mounting from the cylinder
block bracket and withdraw the mounting
assembly.
Transmission bearer and mountings
14 On XR2i models, remove the front
suspension crossmember as described in
Chapter 10.
15 Unscrew and remove the two nuts
securing the mountings (front and rear) to the
transmission bearer
16 Support the transmission bearer, then
undo and remove the four retaining bolts from
the floorpan, two at the front and two at the
rear, and lower the transmission bearer from
the vehicle. Note plate fitment, as applicable,
for reassembly.
17 To remove the mountings from the
transmission, unscrew the upper bolt and
lower stud (front mounting) or the three nuts
(rear mounting) and withdraw the relevant
mounting and bracket assembly from the
transmission.
All mountings
18 Refitting of all mountings is a reversal of
removal. Make sure that the original sequence
of assembly of washers and plates is
maintained.
19 Do not fully tighten any mounting bolts
until they are all located. As the mounting
bolts and nuts are tightened, check that the
mounting rubbers do not twist.
17 Flywheel/driveplate -
removal, inspection and
refitting
3
Removal
1 Remove the transmission (see the relevant
Part of Chapter 7).
2 Where appropriate, remove the clutch
(Chapter 6).
3 Use a centre-punch or paint to make alignment marks on the flywheel/driveplate
and crankshaft, to ensure correct alignment
during refitting.
4
Prevent the flywheel/driveplate from turning
by locking the ring gear teeth, or by bolting a
strap between the flywheel/driveplate and the
cylinder block/crankcase. Slacken the bolts
evenly until all are free.
5 Remove each bolt in turn, and ensure that
new replacements are obtained for
reassembly; these bolts are subjected to
severe stresses, and so must be renewed,
regardless of their apparent condition,
whenever they are disturbed.
6 Noting the reinforcing plate (automatic
transmission models only), withdraw the
flywheel/driveplate; do not drop it - it is very
heavy.
Inspection
7 Clean the flywheel/driveplate to remove
grease and oil. Inspect the surface for cracks,
rivet grooves, burned areas and score marks.
Light scoring can be removed with emery
cloth. Check for cracked and broken ring gear
teeth. Lay the flywheel/driveplate on a flat
surface, and use a straight edge to check for
warpage.
8 Clean and inspect the mating surfaces of
the flywheel/driveplate and the crankshaft. If
the crankshaft left-hand seal is leaking, renew
it (see Section 15) before refitting the
flywheel/driveplate.
9 While the flywheel/driveplate is removed,
clean carefully its inboard (right-hand) face,
particularly the recesses which serve as the
reference points for the crankshaft speed/
position sensor. Clean the sensor’s tip, and
check that the sensor is securely fastened.
Refitting
10 On refitting, ensure that the engine/
transmission adapter plate is in place (where
necessary), then fit the flywheel/driveplate to
the crankshaft so that all bolt holes align - it
will fit only one way - check this using the
marks made on removal. Do not forget the
reinforcing plate (automatic transmission
models).
11 Lock the flywheel/driveplate by the
method used on dismantling. Working in a
diagonal sequence to tighten them evenly,
and increasing to the final amount in two or
three stages, tighten the new bolts to the
specified torque wrench setting.
12 The remainder of reassembly is the
reverse of the removal procedure, referring to
the relevant text for details where required.
2C•16 Zetec engine in-car repair procedures
16.8 Engine front right-hand mounting
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2D
1595Ford Fiesta Remake
HCS engines
Cylinder head
Maximum permissible gasket surface distortion (measured over
full length) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 0.15 mm
Valve seat angle (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45º
Valve seat width (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 to 1.75 mm*
*The inlet and exhaust valves have special inserts which cannot be recut\
using conventional tools.
Valves - generalInletExhaust
Valve length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 103.7 to 104.4 mm 104.2 to 104.7 mm
Valve head diameter: 1.0 and 1.1 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.90 to 33.10 mm 28.90 to 29.10 mm
1.3 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 34.40 to 34.60 mm 28.90 to 29.10 mm
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 7.0 mm 7.0 mm
Valve stem-to-guide clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.069 0.046 to 0.095
Cylinder block
Cylinder bore diameter: 1.0 and 1.1 litre engines:
Standard class 1 (or A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.68 to 68.69 mm
Standard class 2 (or B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.69 to 68.70 mm
Standard class 3 (or C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.70 to 68.71 mm
Oversize 0.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 69.20 to 69.21 mm
Oversize 1.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 69.70 to 69.71 mm
1.3 litre engines:
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 73.94 to 73.95 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 73.50 to 73.96 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 73.96 to 73.97 mm
Oversize 0.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 74.50 to 74.51 mm
Oversize 1.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 75.00 to 75.01 mm
Chapter 2 Part D:
Engine removal and overhaul procedures
Camshaft and tappets - removal, inspection and refitting (HCS engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 10
Crankshaft - refitting and main bearing running clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 17
Crankshaft - removal and inspection . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder block/crankcase - cleaning and inspection . . . . . . . . . . . . 13
Cylinder head - dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder head - reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder head and valve components - cleaning and inspection . . . 8
Engine - initial start-up after overhaul . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine - removal and refitting (HCS engines) . . . . . . . . . . . . . . . . . . 3
Engine overhaul - preliminary information . . . . . . . . . . . . . . . . . . . . . 6 Engine overhaul - reassembly sequence . . . . . . . . . . . . . . . . . . . . . 15
Engine/transmission removal - preparation and precautions . . . . . . 2
Engine/transmission - removal and refitting (CVH and
PTE engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 4
Engine/transmission - removal and refitting (Zetec engines) . . . . . . 5
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1
Main and big-end bearings - inspection . . . . . . . . . . . . . . . . . . . . . . 14
Piston/connecting rod assemblies - refitting and big-end
bearing running clearance check . . . . . . . . . . . . . . . . . . . . . . . . . 18
Piston/connecting rod assemblies - removal and inspection . . . . . . 11
Piston rings - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
16
2D•1
Specifications Contents
Easy, suitable for
novice with little
experience Fairly easy,
suitable
for beginner with
some experience Fairly difficult,
suitable for competent
DIY mechanic
Difficult,
suitable for
experienced DIY
mechanic Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
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Pistons and piston rings
Piston diameter:1.0 and 1.1 litre engines:
Standard class 1 (or A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.65 to 68.66 mm
Standard class 2 (or B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.66 to 68.67 mm
Standard class 3 (or C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.67 to 68.68 mm
Standard (service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 68.67 to 68.70 mm
Oversize 0.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 69.16 to 69.19 mm
Oversize 1.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 69.66 to 69.69 mm
1.3 litre engines:
Standard class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 73.91 to 73.92 mm
Standard class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 73.92 to 73.93 mm
Standard class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 73.93 to 73.94 mm
Oversize 0.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 74.46 to 74.49 mm
Oversize 1.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 74.96 to 74.99 mm
Piston-to-cylinder bore clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 to 0.050 mm
Piston ring end gap - installed: Top compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. 0.25 to 0.45 mmSecond compression ring: 1.0 and 1.1 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.45 mm
1.3 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 0.45 to 0.75 mm
Oil control ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 0.20 to 0.40 mm
Piston ring-to-groove clearance: Compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 0.20 mm (maximum)
Oil control ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 0.10 mm (maximum)
Ring gap position: Top compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. Offset 180º from oil control ring gap
Second compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Offset 90º from oil control ring gap
Oil control ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . Aligned with gudgeon pin
Gudgeon pin
Length: 1.0 and 1.1 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.6 to 59.4 mm
1.3 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 63.3 to 64.6 mm
Diameter:
White colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 18.026 to 18.029 mm
Red colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 18.029 to 18.032 mm
Blue colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 18.032 to 18.035 mm
Yellow colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 18.035 to 18.038 mm
Clearance in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 0.008 to 0.014 mm
Interference fit in connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.016 to 0.048 mm
Crankshaft and bearings
Main bearing journal diameter: 1.0 and 1.1 litre engines:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . 56.990 to 57.000 mm
Standard (with yellow line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.980 to 56.990 mm
0.254 mm undersize (with green line) . . . . . . . . . . . . . . . . . . . . . . . 56.726 to 56.746 mm
0.508 mm undersize (service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.472 to 56.492 mm
0.762 mm undersize (service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.218 to 56.238 mm
1.3 litre engines: Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . 56.980 to 57.000 mm
0.254 mm undersize (with green line) . . . . . . . . . . . . . . . . . . . . . . . 56.726 to 56.746 mm
0.508 mm undersize (service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.472 to 56.492 mm
0.762 mm undersize (service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.218 to 56.238 mm
Main bearing journal-to-shell running clearance:
1.0 and 1.1 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.009 to 0.046 mm
1.3 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 0.009 to 0.056 mm
Crankpin (big-end) bearing journal diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 40.99 to 41.01 mm
0.254 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 40.74 to 40.76 mm
0.508 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 40.49 to 40.51 mm
0.762 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 40.24 to 40.26 mm
Crankpin (big-end) bearing journal-to-shell running clearance . . . . . . . 0.006 to 0.060 mm
Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 0.100 to 0.250 mm
Thrustwasher thickness: Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 2.80 to 2.85 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 2.99 to 3.04 mm
2D•2 Engine removal and overhaul procedures
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Camshaft
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . 0.02 to 0.19 mm
Torque wrench settingsNmlbf ft
Main bearing cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 9570
* Crankpin (big-end) bearing cap bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 4 3
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Angle-tighten a further 90º
Engine-to-transmission bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4130
* New bolts must be used
Note: Refer to Part A of this Chapter for remaining torque wrench settings.
CVH and PTE engines
Cylinder head
Maximum permissible gasket surface distortion (measured over
full length) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 0.15 mm
Camshaft bearing bore diameters in cylinder head (standard): Bearing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 44.783 to 44.808 mm
Bearing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.033 to 45.058 mm
Bearing 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.283 to 45.308 mm
Bearing 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.533 to 45.558 mm
Bearing 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.783 to 45.808 mm
Camshaft bearing bore diameters in cylinder head (oversize): Bearing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.188 to 45.163 mm
Bearing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.438 to 45.413 mm
Bearing 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.668 to 45.663 mm
Bearing 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 45.938 to 45.913 mm
Bearing 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 46.188 to 46.163 mm
Valve tappet bore diameter (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . 22.235 to 22.265 mm
Valve tappet bore diameter (oversize) . . . . . . . . . . . . . . . . . . . . . . . . . . 22.489 to 22.519 mm
Valve seat angle (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44º 30’ to 45º 30’
Valve seat width (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.75 to 2.32 mm*
*The cylinder head has valve seat rings on the exhaust side. These valve\
seats cannot be recut with conventional tools.
Valves - generalInlet Exhaust
Valve length: 1.4 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 136.29 to 136.75 mm 132.97 to 133.43 mm
1.6 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 134.54 to 135.00 mm 131.57 to 132.03 mm
Valve head diameter:
1.4 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 39.90 to 40.10 mm 33.90 to 34.10 mm
1.6 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 41.90 to 42.10 mm 36.90 to 37.10 mm
Valve stem diameter (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.025 to 8.043 mm 7.999 to 8.017 mm
Valve stem diameter (0.2 mm oversize) . . . . . . . . . . . . . . . . . . . . . . . . . 8.225 to 8.243 mm 8.199 to 8.217 mm
Valve stem diameter (0.4 mm oversize) . . . . . . . . . . . . . . . . . . . . . . . . . 8.425 to 8.443 mm 8.399 to 8.417 mm
Valve stem-to-guide clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.063 mm 0.046 to 0.089 mm
Cylinder block
Cylinder bore diameter:
1.4 litre engine: Standard 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 77.22 to 77.23 mm
Standard 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 77.23 to 77.24 mm
Standard 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 77.24 to 77.25 mm
Standard 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 77.25 to 77.26 mm
Oversize A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 77.51 to 77.52 mm
Oversize B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 77.52 to 77.53 mm
Oversize C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 77.53 to 77.54 mm
1.6 litre engine: Standard 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 79.94 to 79.95 mm
Standard 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 79.95 to 79.96 mm
Standard 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 79.96 to 79.97 mm
Standard 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 79.97 to 79.98 mm
Oversize A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 80.23 to 80.24 mm
Oversize B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 80.24 to 80.25 mm
Oversize C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 80.25 to 80.26 mm
Engine removal and overhaul procedures 2D•3
2D
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Pistons and piston ringsPiston diameter (production):1.4 litre engine:
Standard 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 77.190 to 77.200 mm
Standard 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 77.200 to 77.210 mm
Standard 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 77.210 to 77.220 mm
Standard 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 77.220 to 77.230 mm
Oversize A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 77.480 to 77.490 mm
Oversize B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 77.490 to 77.500 mm
Oversize C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 77.500 to 77.510 mm
1.6 litre carburettor engine and turbocharged engine:
Standard 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 79.910 to 79.920 mm
Standard 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 79.920 to 79.930 mm
Standard 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 79.930 to 79.940 mm
Standard 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 79.940 to 79.950 mm
Oversize A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 80.200 to 80.210 mm
Oversize B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 80.210 to 80.220 mm
Oversize C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 80.220 to 80.230 mm
1.6 litre EFi (non-turbo) fuel injection engine: Standard 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 79.915 to 79.925 mm
Standard 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 79.925 to 79.935 mm
Standard 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 79.935 to 79.945 mm
Standard 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 79.945 to 79.955 mm
Oversize A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 80.205 to 80.215 mm
Oversize B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 80.215 to 80.225 mm
Oversize C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 80.225 to 80.235 mm
Piston-to-cylinder bore clearance: 1.4 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 0.020 to 0.040 mm
1.6 litre carburettor engine and turbocharged engine . . . . . . . . . . . . 0.020 to 0.040 mm
1.6 litre EFi (non-turbo) fuel injection engine . . . . . . . . . . . . . . . . . . . 0.015 to 0.035 mm
Piston ring end gaps - installed:
Compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 0.30 to 0.50 mm
Oil control rings:1.4 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 0.40 to 1.40 mm
1.6 litre carburettor engine and turbocharged engine . . . . . . . . . . 0.40 to 1.40 mm
1.6 litre EFi (non-turbo) fuel injection engine . . . . . . . . . . . . . . . . . 0.25 to 0.40 mm
Gudgeon pins
Length:1.4 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 63.000 to 63.800 mm
1.6 litre carburettor engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.200 to 67.000 mm
1.6 litre EFi (non-turbo) fuel injection engine . . . . . . . . . . . . . . . . . . . 63.000 to 63.800 mm
1.6 litre turbocharged engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.600 to 64.400 mm
Diameter: White colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 20.622 to 20.625 mm
Red colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 20.625 to 20.628 mm
Blue colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 20.628 to 20.631 mm
Yellow colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 20.631 to 20.634 mm
Clearance in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 0.005 to 0.011 mm
Interference fit in connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.013 to 0.045 mm
Crankshaft and bearings
Main bearing journal diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 57.98 to 58.00 mm
0.25 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 57.73 to 57.75 mm
0.50 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 57.48 to 57.50 mm
0.75 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 57.23 to 57.25 mm
Main bearing journal-to-shell running clearance . . . . . . . . . . . . . . . . . . 0.011 to 0.058 mm
Crankpin (big-end) bearing journal diameter: Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 47.89 to 47.91 mm
0.25 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 47.64 to 47.66 mm
0.50 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 47.39 to 47.41 mm
0.75 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 47.14 to 47.16 mm
1.00 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 46.89 to 46.91 mm
Crankpin (big-end) bearing journal-to-shell running clearance . . . . . . . 0.006 to 0.060 mm
Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 0.09 to 0.30 mm
Thrustwasher thickness: Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 2.301 to 2.351 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 2.491 to 2.541 mm
2D•4 Engine removal and overhaul procedures
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Torque wrench settingsNmlbf ft
Main bearing caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 9570
Crankpin (big-end) bearing caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3324
Engine-to-transmission bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4130
Note: Refer to Part B of this Chapter for remaining torque wrench settings.
Zetec engines
Cylinder head
Maximum permissible gasket surface distortion . . . . . . . . . . . . . . . . . . 0.10 mm
Valve seat included angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
90º
Valve guide bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 6.060 to 6.091 mm
Valves - generalInlet Exhaust
Valve length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 96.870 to 97.330 mm 96.470 to 96.930 mm
Valve head diameter: 1.6 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 26.0 mm 24.5 mm
1.8 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 32.0 mm 28.0 mm
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 6.028 to 6.043 mm 6.010 to 6.025 mm
Valve stem-to-guide clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.017 to 0.064 mm 0.035 to 0.081 mm
Cylinder block
Cylinder bore diameter: 1.6 litre engine: Class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 76.000 to 76.010 mm
Class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 76.010 to 76.020 mm
Class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 76.020 to 76.030 mm
1.8 litre engine:
Class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 80.600 to 80.610 mm
Class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 80.610 to 80.620 mm
Class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 80.620 to 80.630 mm
Pistons and piston rings
Piston diameter1.6 litre engine: Class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 75.975 to 75.985 mm
Class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 75.985 to 75.995 mm
Class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 75.995 to 76.005 mm
1.8 litre engine:
Class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 80.570 to 80.580 mm
Class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 80.580 to 80.590 mm
Class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 80.590 to 80.600 mm
Oversizes - all engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
None available
Piston-to-cylinder bore clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not specified
Piston ring end gaps - installed: Compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 0.30 to 0.50 mm
Oil control ring: 1.6 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 0.25 to 1.00 mm
1.8 litre engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 0.38 to 1.14 mm
Gudgeon pin
Diameter:
White colour code/piston crown marked “A” . . . . . . . . . . . . . . . . . . . 20.622 to 20.625 mm
Red colour code/piston crown marked “B” . . . . . . . . . . . . . . . . . . . . 20.625 to 20.628 mm
Blue colour code/piston crown marked “C” . . . . . . . . . . . . . . . . . . . . 20.628 to 20.631 mm
Clearance in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 0.010 to 0.016 mm
Interference fit in connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.011 to 0.042 mm
Crankshaft and bearings
Main bearing journal standard diameter . . . . . . . . . . . . . . . . . . . . . . . . . 57.980 to 58.000 mm Main bearing journal-to-shell running clearance . . . . . . . . . . . . . . . . . . 0.011 to 0.058 mm
Main bearing shell undersizes available . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm, 0.25 mmCrankpin (big-end) bearing journal standard diameter . . . . . . . . . . . . . . 46.890 to 46.910 mm
Crankpin (big-end) bearing journal-to-shell running clearance . . . . . . . 0.016 to 0.070 mm
Big-end bearing shell undersizes available . . . . . . . . . . . . . . . . . . . . . . 0.02 mm, 0.25 mm
Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 0.090 to 0.310 mm
Engine removal and overhaul procedures 2D•5
2D
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